Installation of 2Q-7848 Axle Oil Cooler (Kit-Axle Oil Cooler ) {1365} Caterpillar

Wheel Loader:

966G Series II (S/N: ANT1-UP; ANZ1-UP)

972G Series II (S/N: ANY1-UP; AWP1-UP)

Introduction

This publication contains the information for installation of the Axle Oil Cooler. A complete listing of the parts that are contained in this kit are listed in the Parts Manual, SEBC1350. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Do not perform any procedure and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

Machining of the Axle Center Housings

Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

1. Remove the front fixed axle. Refer to Disassembly and Assembly, RENR2106, "Fixed Axle (Front) - Remove and Install".

2. Remove the rear oscillating axle. Refer to Disassembly and Assembly, RENR2106, "Oscillating Axle (Rear) - Remove". Also refer to Disassembly and Assembly, RENR2106, "Oscillating Axle (Rear) - Install".

3. Remove the differential and bevel gears from both axles. Refer to Disassembly and Assembly, RENR2106, "Differential and Bevel Gear - Remove". Also refer to Disassembly and Assembly, RENR2106, "Differential and Bevel Gear - Install".

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Illustration 1	g00793869
View of the axle center housing (C) 187 mm (7.36 inch) (D) 117.5 mm (4.62 inch) (E) 48 mm (1.889 inch) (F) 40.5 mm (1.59 inch) (G) 20 mm (0.78 inch) (H) 121 mm (4.76 inch) (J) 250 mm (9.84 inch) (K) 240 mm (9.44 inch) (L) 188 mm (7.40 inch) (M) 178 mm (7.00 inch) (N) 243 mm (9.56 inch) (P) 29 mm (1.14 inch) (R) 164 mm (6.45 inch) (S) 253 mm (9.96 inch) (T) 220 mm (8.66 inch) (U) 194.5 mm (7.65 inch) (V) 176.65 mm (6.95 inch) (W) 196.19 mm (7.72 inch) (X) 77.5 mm (3.05 inch) (Y) 252.37 mm (9.93 inch) (Z) 77.5 mm (3.05 inch) (AA) 252.37 mm (9.93 inch) (BB) 16 mm (0.63 inch) (CC) 0.8 ± 0.2 mm (0.03 ± 0.0079 inch) Radius on three surfaces (DD) 276 mm (10.86 inch) Radius on three surfaces (EE) 1.6 ± 0.4 mm (0.063 ± 0.015 inch)

4. Refer to Illustration 1 in order to locate the dimensions for the machining process.

   Note: The same machining is required on both of the axle center housings.

5. Machine the front axle center housing.

6. Machine the rear axle center housing.

Installation of 160-0719 Axle Heat Exchanger

Note: Refer to Disassembly and Assembly, RENR2106, "Heat Exchanger (Axle Oil Cooler) - Remove and Install".

Installation of 145-9537 Axle Oil Cooler Lines Gp

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Illustration 2	g00792527
Right side view of rear frame (A) Hose (FF) Elbow (GG) Elbow

1. Remove existing hose (A) .

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Illustration 3	g00792593
Right side view of loader frame assembly

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Illustration 4	g00792639
Top view of loader frame

2. Install two 6V-8981 Elbows (1). Secure the two 6V-8981 Elbows (1) with two 6V-9169 Bulkhead Nuts (2) .

3. Install one 6V-8398 O-Ring Seal (5) into one end of 151-6417 Tube As (3). Connect 151-6417 Tube As (3) to the top 6V-8981 Elbow (1).

4. Install one 6V-8398 O-Ring Seal (5) into the other end of 151-6417 Tube As (3). Install one 6V-8731 Face Seal Union (6) into 151-6417 Tube As (3).

5. Install one 6V-8398 O-Ring Seal (5) into one end of 151-6420 Tube As (4) . Connect 151-6420 Tube As (4) to the bottom 6V-8981 Elbow (1).

6. Install one 6V-8398 O-Ring Seal (5) into the other end of 151-6420 Tube As (4). Install one 6V-8731 Face Seal Union (6) into 151-6420 Tube As (4) .

7. Secure the 151-6417 Tube As (3) and the 151-6420 Tube As (4) with the following hardware:
   • One 8T-4121 Hard Washer (7)

   • One 8T-4133 Nut (8)

   • One 1B-3057 Clip (9)

8. Install one 6V-8398 O-Ring Seal (5) into one end of 152-1872 Hose As (39). Connect 152-1872 Hose As (39) onto 151-6420 Tube As (4).

9. Install one 6V-8398 O-Ring Seal (5) into the other end of 152-1872 Hose As (39). Connect 152-1872 Hose As (39) onto the front axle oil cooler.

10. Install one 6V-8398 O-Ring Seal (5) into one end of 152-1870 Hose As (40). Connect 152-1870 Hose As (40) onto 151-6417 Tube As (3).

11. Install one 6V-8398 O-Ring Seal (5) into the other end of 152-1870 Hose As (40). Connect 152-1870 Hose As (40) onto the front axle oil cooler.

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Illustration 5	g00792813
Partial top view of rear frame assembly

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Illustration 6	g00792913
Partial right side view of rear frame assembly

12. Install two 6V-8995 Bulkhead Unions (11) onto the 180-9312 Plate (10). Secure the two 6V-8995 Elbows (11) with two 6V-9169 Bulkhead Nuts (2) .

13. Use the following hardware in order to install 180-9312 Plate (10) :
    • Two 8T-4196 Bolts (12)

    • Four 8T-4121 Hard Washers (7)

    • Two 8T-4133 Nuts (8)

14. Connect two 4E-6865 Hose Assemblies (17) onto the two 6V-8981 Elbows (1). Refer to the Illustration 4.

15. Connect the other end of the two 4E-6865 Hose Assemblies (17) onto 6V-8995 Bulkhead Union (11). Refer to Illustration 5.

16. Install 6V-8731 Face Seal Union (6) onto 198-1208 Tube As (14) .

17. Install 6V-8731 Face Seal Union (6) onto 198-1207 Tube As (13) .

18. Connect 198-1208 Tube As (14) onto the lower 6V-8995 Bulkhead Union (11) .

19. Connect 198-1207 Tube As (13) onto the upper 6V-8995 Bulkhead Union (11) .

20. Use the following hardware to secure the 198-1208 Tube As (14) and the 198-1207 Tube As (13) :
    • Two 124-0174 Clips (15)

    • Two 8T-4186 Bolt (16)

    • Two 8T-4121 Hard Washer (7)

    • One 8C-3373 Washer (29)

    • Two 4B-0418 Clips (28)

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Illustration 7	g00792996
Partial right side view of rear frame assembly (FF) Elbow (GG) Elbow

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Illustration 8	g00793022

21. Use the following hardware in order to mount the 197-8882 Flow Divider Valve (26) onto the 150-8746 Plate (18) :
    • Two 7X-2545 Bolts (25)

    • Two 8T-4121 Hard Washers (7)

    • Two 8T-4133 Nuts (8)

22. Install two 3K-0360 O-Ring Seal (21) into the 197-8882 Flow Divider Valve (26). Install two 6V-8639 Connectors (20) onto the 197-8882 Flow Divider Valve (26).

23. Install two 3K-0360 O-Ring Seals (21) into the 197-8882 Flow Divider Valve (26). Install two 6V-9002 Elbows (22) onto the 197-8882 Flow Divider Valve (26).

24. Install one 3D-2824 O-Ring Seal (23) into the 197-8882 Flow Divider Valve (26). Install one 6V-9007 Elbow (27) onto the 197-8882 Flow Divider Valve (26).

25. Install one 3D-2824 O-Ring Seal (23) into the 197-8882 Flow Divider Valve (26). Install one 6V-9004 Elbow (24) onto the 197-8882 Flow Divider Valve (26).

26. Use the following hardware in order to mount the 150-8746 Plate (18) onto the air inlet support:
    • Two 8T-4121 Hard Washer (7)

    • Two 8T-4195 Bolts (19)

27. Install one 6V-8398 O-Ring Seal (23) into one end of the 151-6410 Hose As (35). Connect 151-6410 Hose As (35) to 197-8882 Flow Divider Valve (26).

28. Install one 6V-8398 O-Ring Seal (23) into the other end of 151-6410 Hose As (35). Connect the 151-6410 Hose As (35) to the rear axle oil cooler.

29. Install one 6V-8398 O-Ring Seal (23) into one end of the 151-6411 Hose As (36). Connect 151-6411 Hose As (36) to 197-8882 Flow Divider Valve (26).

30. Install one 6V-8398 O-Ring Seal (23) into the other end of 151-6411 Hose As (36). Connect 151-6411 Hose As (36) to the rear axle oil cooler.

31. Use the following hardware to secure 151-6410 Hose As (35) and 151-6411 Hose As (36) :
    • Two 6D-4246 Clips (37)

    • One 8T-4121 (7)

    • One 8T-4195 Bolt (19)

32. Install one 6V-9746 O-Ring Seal (31) into one end of 159-8322 Hose As (38). Connect 159-8322 Hose As (38) to 197-8882 Flow Divider Valve (26).

33. Connect the other end of the 159-8322 Hose As (38) onto elbow (FF). Refer to Illustration 2.

34. Install one 6V-9746 O-Ring Seal (31) into 151-6421 Hose As (30). Connect 151-6421 Hose As (30) to 197-8882 Flow Divider Valve (26) .

35. Connect the other end of the 151-6421 Hose As (30) onto elbow (GG). Refer to Illustration 2.

36. Use the following hardware to secure 151-6421 Hose As (30) :
    • Three 4S-1962 Clips (32)

    • One 8T-4121 Hard Washer (7)

    • One 8T-4133 Nut (8)

37. Install one 6V-8398 O-Ring Seal (5) into the 151-6413 Hose As (33). Connect 151-6413 Hose As (33) to 197-8882 Flow Divider Valve (26).

38. Install one 6V-8398 O-Ring Seal (5) into the other end of 151-6413 Hose As (33). Connect 151-6413 Hose As (33) to 198-1207 Tube As (13). Refer to Illustration 6.

39. Install one 6V-8398 O-Ring Seal (5) into 151-6414 Hose As (34). Connect 151-6414 Hose As (34) to 197-8882 Flow Divider Valve (26) .

40. Install one 6V-8398 O-Ring Seal (5) into the other end of 151-6413 Hose As (33). Connect 151-6413 Hose As (33) to 198-1208 Tube As (14). Refer to Illustration 6.

Removal of the existing Oil Cooler Core

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Illustration 9	g00921357
Rear view of the Radiator and Fan Group (C) Bolts and washers (D) Bracket assembly (E) Bolts and washers (F) Cooler Core Assembly for the Hydraulic Oil

1. Remove the four Bolts and four Washers (C) that hold the Bracket Assembly (D). Remove the Bracket Assembly (D). The four Bolts and four Washers (C) will be reused.

2. Remove the four Bolts and four Washers (E) that hold the Cooler Core Assembly (F). Remove the Cooler Core Assembly (F). The four Bolts and four Washers (E) will be reused.

Installation of the 216-8642 Oil Cooler Core

1. Refer to Illustration 9. Use the four Bolts and four Washers (E) and install the 216-8642 Oil Cooler Core .

2. Refer to Illustration 9. Use the four Bolts and four Washers (C) and install the Bracket Assembly (D) onto the 216-8642 Oil Cooler Core .